American Journal of Multidisciplinary Research & Development (AJMRD)

Volume 04, Issue 07 (July - 2022), PP 01-08

ISSN: 2360-821X
www.ajmrd.com

Research Paper Open Access

“Defect analysis and remedies in the High Pressure Diecasting

Process with ADC-12 Alloy”. – A Technical review.
R.Govindarao1* Dr.K.Eshwara P Srinivasa Rao3
2
Research Scholar Prasad(Rted) Research Scholar
Jawaharlal Nehru Technological Professor&Principal, Jawaharlal Nehru Technological
University, Department of University,
Hyderabad, Telangana, Mechanical Hyderabad, Telangana,
India Engineering India.
Jawaharlal Nehru
Technological University,
Hyderabad, Telangana,
India.

Abstract: In the present automotive supply chain the suppliers are facing the more diecasting defects. Most
ofthe automotive manufacturers are changing the products from heavy weight components to lower weight
likealuminum. The High pressure diecasting (HPDC) process is the most vital engineering process in which
thecomponents are produced with low weight and high productivity. During this process the components
foundwith more abnormalities as casting defects in both internal and external .This paper is presenting to
avoid suchtype of defects in the HPDC process.

Key words: HPDC Process, internal defects, external defects

I. Introduction:
The HPDC process consists of one horizontal diecasting machine with one mould and the holding furnace. The
metal is transferred to the shot sleeve chamber through the autoladle.Metal is poured into the shot sleeve by auto
ladle and injection process is carried by the separate injection system with the high velocity (2m/sec – 4.5
m/sec) and high pressure (600kg/cm2 to 800600kg/cm2).The mould is filled and allow to solidify with some time
(Min-4sec to Max15 Sec) depending up on the wall thickness of the casting. Casting is ejected by the ejection
system and to be collected by the operator or special extractor mechanism. Specialchemical (water is mixed with
coolant in 1:200 ratio) water is sprayed on die halves to cool the mould and to form micro film upon the mould
to easy release of the casting. Next cycle process will be repeated.

High pressure
HIGH die casting
PRESSURE DIECASTING cycle
MACHINE CYCLEprocess.
TIME.

(10) (1)
Side Core
in
(9) (2)

(3)
(8)

(4)
(7)
Side cores out
(6)
(5)
Die Open

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 “Defect analysis and remedies in the High Pressure Diecasting Process with...

II. Diecasting defects:

In High Pressure Die casting process we found more defects in the process. These defects are
pertaining to both surface defects and the internal defects. The surface defects and internal defects are subjected
to be change depend up on the casting geometry, surface area of the component and selection of the machine.
The ADC-12 [1] alloy is used most of the automobile industry.
All defects are not depending upon the multiple Parameters .The main root cause of the defect is only
one or two.Optimisation of the all parameters will leads to create another defects. The Parameters are defined
basically in two forms one is Constant and other one is Variable parameters .The Constant parameters are
belongs to tool/Die and the Machine. To reduce the defects means we have to focus on variable parameters. The
variable parameters are changing due to mechanical losses, the electrical losses and some frictional losses. The
defect is one of the abnormalities in the process which can be rectified. The increment in internal rejections will
be impact on company’s profitability indirectly.
The causes for the defects will categorize in two ways. One is assignable causes (probable causes) and
other one is the variable causes. Probable causes are rectified by the experience team and the assignable causes
are requiredthe management support like in the tool modification, Machine part replacement or purchase the
new equipment to rectifythe particular problem.
In this paper we are highlighting the major defects which are occurring in the high pressure diecasting process
and its remedies. This paper has been presenting by an experienced research scholar. If the surface defects are
more than 5 % it can be resolved by the correction in the tool/die and machine parameters and if the defects are
under 5% needs another improvement in the above Both. In addition to the above it is required to examine
some other parameters also like man, methods, materials and process. The HPDC defects can be classified as

CLASSIFICATION OF DEFECTS

Surface defects or visual defects internal defects/After machining defects

I. Cold shut 1.Blow hole
II. Crack 2.Inclusion
III. Drag3.Shrinkage porosity
IV. Damage
V. Chip off
VI. Gate blow hole
VII. Peel off
VIII. Blisters
IX. Soldering

2.1Surface defects:
2.1.1 Cold shut:The cold shot is categorized as
surface defect because of it can be found out by
visual. This type surface defect is predominant Cold shut
causing the more rejections in the High pressure die
casting process. The main causes and remedies are
under:

Fig: 1

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 “Defect analysis and remedies in the High Pressure Diecasting Process with...

Parameter Root causes Remedies

1. Water leak into the die cavity 1.Correct the water leakages
2. Overflow blocked. 2.open the over flows
3. Vent locked 3.Open the vents
Die 4. Flash from the die. 4.1.Blue match the die inserts and maintain the
insert position to be more than 0.5mm than
housing
4.2. Avoid higher range of machine parameters.
1. Lower metal temperature (<6200C) 1.Maintain metal temperature between 6600C -
2. More die coat spray > 10 sec 680 0C
3. Due to plunger tip dragging the First and 2. Maintain die coat spray according to die
Process second phase velocities are not acting properly temperature to be maintain (1800C -2200C) after
4. Flash from plunger tip. spray.
5. Fast shot too delayed.(<2.0 m/sec) 3.Verify the tip lubrication and maintain constant
volume (2ml/shot)
4. Check the tip alignment with the machine and
control the tip wear out/ Change the plunger tip
5. Fast shot speed to be maintain 3.5m/sec – 4.5
m/sec
1. Biscuit thickness should be (20mm-30mm) 1. Verify the ladle is carrying the designed
2. ACC pressure shot not effective (shows quantity of metal is transferring in each cycle.
Lower value as designed by manufacturer) 2.1. Set the Accumulator value and observe in
each cycle.
Machine 2.2. Maintain Hydraulic oil [2] temperature less
than 550C

1. Low Si content (<8%) 1.Verify the Silicon content it should be 9.0% -

2. Diecoat dilution High (< 1:100) 12.0%
Material 3. Fe content is less (<0.8%) 2. Diecoat dilution should be 1:200 as designed
by the supplier.
3.Fe content should be 0.8% to 1.3%
1. Intensification pressure is low 1.Training to be provide to the operator on
2. Cycle time more. machine parameters on intensification pressure
Man 3. Less air spray (water content remains [3] application to be maintain up to 250 kg/cm
inside cavity) 2.Optimize the cycle time
3.Apply more air into the die cavity
Table: 1

2.1.2 Crack:
The crack [4] is found where the thin walled
casting is producing in HPDC process. Some Crack
castings wall thickness configuration is changing
from thin section to thick section then there will be
chance of crack defect. Simultaneously If wall
thickness less than 2 mm with more casting area
there will be occurrence of crack defect.

Fig:2
Parameter Root causes Remedies
1. Ejection Force is too high 1.Maintain medium ejection force
2. Shorten hold (dwell) time to get the casting out of the 2.Ejection forward time should be
die sooner (Max.1 sec) 1sec after machine open
3. Improper machine platen alignment. 3.Align the machine platen top to
Machine 4. Die opening speed more. bottom less than 0.3mm
5. Less die coat spray. 4.Redue the die opening speed
5. Die coat spray should be sufficient
as per the casting profile.

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 “Defect analysis and remedies in the High Pressure Diecasting Process with...

1.Insuffient Draft angle 1. Draft angle should 7be 1-2Degree

2.Check that bumper rods are all exactly the same length. 2. Bumper rods should be exactly the
3. Check that the bumper plate is not bent or loose. same length
4. Slow down the ejection action (if possible) so as to be 3.Check the tool back plate tight ness
able to observe carefully. 4.Ejection forward speed should be
5. Watch for uneven ejection, i.e., the ejector plate twists slow in motion
during ejection. 5. Up and down ejection should be
6.Check for good radius at the crack location avoided.
Die 7. The runner and biscuit area is too hot. 6. 1R or 2R depending on casting
8.Heat up adjacent space cool spots profile
9.Ejector plate Bend 7.Provide cooling to the runner and
10.Die internal stresses are more[5] spreader
8.Provide spot cooling at the crack
area
9.Provide without bend ejection plate
in the die
10.Sent for stress relieving after
completion for

1. Less die coat dilution. 1. Diecoat dilution should be 1:200 as

Process 2.Soldering in die designed by the supplier
3. Higher metal temperature. 2.Provide extra spray line at the location
4.Less die coat spray 3. Maintain metal temperature between
5.Biscuit catch up in plunger tip 6600C -680 0C
6.More gate velocity[6] 4. Provide spray time as designed
5.Cool the plunger tip
6.Maintain gate velocity as 50
m/sec- 60m/sec
Material Low Fe content Fe content should be 0.8% to 1.3

Table:2
2.1.3 Unfillling: It is also called as nonfilling and it
comes under the surface defect. This defect is
usually found in the HPDC process.Unfilling
contribution in HPDC process is nearly 2-3% of the Unfilling
total rejection.

Fig: 3
Parameter Root causes Remedies
1.Specific Injection Pressure[7] is too Low 1.Depending upon the customer
(<600 kg/cm2) requirement Specific Injection Pressure to
2. Casting Velocity V2 is Too Slow. be maintain 600 kg/cm2-850 kg/cm2
(< 2.0 m/sec ) 2. Fast shot speed to me maintain
Machine 3.Check ACC pressure Build Up 3.5m/sec – 4.5 m/sec
( Pressure should reach before die closing 3.1. Set the Accumulator pressure value
4.Auto ladle carrying the un even volume if metal and observe it in each cycle.
3.2.Maitain Hydraulic oil temperature
less than 550C

1. Insuffient Over flows (or) Insufficient Over flow 1.Over flow volume to be increased by
volume. 20% and Provide extra overflows at that
Die 2.Less metal feeding area
3.Metal flows in zigzag path 2. Increase the gate thickness and metal
feed.
3.Runner design to make in such a way
that flow always parallel to vertical axis

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 “Defect analysis and remedies in the High Pressure Diecasting Process with...

of the component
1.Low metal temperatures 1. Maintain metal temperature between
Process 2.Insufficient die temperatures 6600C -680 0C
3.Less biscuit thickness 2. Die temperature [10]to be maintain
(1800C -2300C) after spray
3. Biscuit thickness to be maintained
between 20mm-30mm always.

Table: 3

2.1.4 Blister:
Blister [8] is the surface defect in which the casting Blister
surface is uneven and having convex surface. It is
formed due to the more mould having more
temperature .It is having less than 1% in the HPDC
process.

Fig:4
Parameter Root causes Remedies

Machine 1. Casting Velocity V2 is Too Slow. 1. Fast shot speed to be maintain

2.Filling Rate is Too Slow 3.5m/sec – 4.5 m/sec
2. Filling rate [9] should be less than 40
milliseconds according to casting
geometry.

Die 1. Die is Too Hot. 1. Die temperature [10] to be maintain

2. Insuffient Die Venting. (1800C -2200C) after spray
2.Die venting to be increase

PROCESS 1.Less Die Lubricant 1. Provide extra spray line at the location

Table: 4
Soldering 2.1.5:
The soldering is the property of the die to catch the
metal if the diecoat microfilm has been
removed.This happened when the die got more heat Soldering
.Due this problem it is difficult to get dimentional
accuracy .It happening where the draft is less and
misalignment between the fixed and moving halves
of the die.

Fig:5

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 “Defect analysis and remedies in the High Pressure Diecasting Process with...

Parameter Root causes Remedies

1.Slow shot Speed in lower side 1. Slow shot Speed to be maintain between 0.18m/sec
-0.2 m/sec
2.Fast shot Start Point 2. To be provide as per the claculation
3.Add cooling lines specifically 3.Spot cooling to be added at the location of soldering
at the point of soldering, control 4.Increase the water flow if cooling is available
Machine 4.water flow as needed 5.Provide extra spray line at the location
5. spray in the solder 6. Use high heat transfer steel inserts
Area verfication
6.Low heat transfer steel inserts

1.Insufficent spray 1. Provide extra spray line at the location

2.High metal temparature 2. Maintain metal temperature between 6600C -680 0C
3.Less draft 3.Draft to be increase
4.Misalighment between fixed platen to 4.Alignment to be 0-0 between two platens
Process moving platen 5.To be maintain 0.05mm - 0.45mm
5. Gap between Tie bar to machine platen
is more
Man 1.spray lines disturbance 1.Check the spraylines condition every two hours
once.
Table: 5

2.2 Internal defects :

2.2.1Shrinkage Porosity: Porosity is attributed
mainly by gas entrapment. Most alloys have a
higher density in their solid state as compared to
their density in the liquid state. As a result, Shrinkage
shrinkage porosity forms during solidification [12].
Due to the turbulent manner the metal enters and
fills the die cavity, gas often becomes entrapped in
the metal, resulting in porosity. The shrinkage
porosity is having interconnectivity between two
holes. It will appear when the when the part/casting
Fig:6
going to an machining operation.
Parameter Root causes Remedies
1. Specific Injection Pressure is too Low. 1. Depending upon the customer requirement
2.Casting Velocity V2 is Too Fast Specific Injection Pressure to be maintain 600
3.The amount of metal pressure applied at the kg/cm2-850 kg/cm2
end of the plunger stroke or final intensified 2.Fast shot speed to be maintain
metal pressure too low 3.5m/sec – 4.5 m/sec
4.Low metal temperature 3.Intesification pressure to be maintain more
Machine 5. Insufficient water cooling at location than 250 kg/cm2
To extract the heat. 4.Maintain metal temperature between 6600C
6.First phase velocity is too low -680 0C
7. First phase length variation. 5. Provide spot cooling at the crack area
6.Slow shot Speed to be maintain between
0.18m/sec -0.2 m/sec
7. To be provide as per the design and fine
tune until get the result.

Die 1. Insuffient Die Venting. 1.Suffient venting to be provide as per the

2.Die Is Too Cold design
3.Less feed of metal 2. Die temperature to be maintain (1800C -
4. Improper metal feed due to Casting 2200C) after spray
configuration 3.Increase the gate thickness by 30%
4. Runner location to be change parallel to
defect location.

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 “Defect analysis and remedies in the High Pressure Diecasting Process with...

Process 1.Less Die Lubricant 1.Increase the spray time by 2 sec from the
2.Water in the shot sleeve existing one
2.Provide air in the shot sleeve [13]

Table: 6
2.2.2 Blow hole: Porosity is the formation of voids
inside the castings either through the entrapment of
Blowhole
gas or improper pressure configuration in HPDC
machines. Porosity is one of the most difficult
defects to eliminate in die casting. If the porosity
diameter is more than the 0.4mm it is called as
blow hole [14]. The industry sometimes has to
settle to move porosity to a different location in a
casting rather than to remove it completely. The
porosity is not eliminated completely from the
castings and it is not always possible to do with the
current level of Diecasting process .Gas porosity
[15] is forming at the time of solidification where
the internal gases present in the mould. In addition,
attempts to eliminate porosity defects in castings Fig:7
can affect other process settings and results in other
casting defects.
Parameter Root causes Remedies
1. Specific Injection Pressure is too Low. 1. Depending upon the customer requirement
2.Casting Velocity V2 is Too Fast Specific Injection Pressure to be maintain 600
3.Filling Rate is Too Slow kg/cm2-850 kg/cm2
4.Pour Rate (delay Time Before Shot) 2.Fast shot speed to be maintain
5.Slow Shot speed high 3.5m/sec – 4.5 m/sec
6.Change Over Point 3.Filling rate to be increase as pe the design
4. Shot delay time should nor more than 1.0sec.
5. Slow shot Speed to be maintain between
Machine 0.18m/sec -0.2 m/sec
6. Change over point from slow shot to fast shot
to be as per the design calculations.

1. Insuffient Die Venting. 1. Suffient venting to be provid as per the design

2.Die Is Too Cold 2. Die temperature to be maintain (1800C -
3.Insuffient over flow Volume 2300C) after spray
4. Die Flashings. 3.Over flow volume to be increased by 20% and
5.Runner area mismatch Provide extra overflows at that area
6.Vents are not in best location 4.Avoid flashing with proper Blue matching
5.Runner are always to be in the convergent
mode from start point to end point,
Die 6.Vents to be provide where the internal to be
escape out easily

1.More gases in the metal 1. Make degassing process with

Process 8.Filling ration is less degassing machine[16]
2. Filling ration is between 50%-70%

Table: 7

III. Conclusion:
In present days the diecasters are facing the major diecasting defects like nonfilling and cold shuts and
internal defects. These defects are in the range of 3% to 5%.The main reasons for those defects are contributing
both tool and the machine and the process. But the contribution of internal defects like blow holes and

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 “Defect analysis and remedies in the High Pressure Diecasting Process with...

shrinkages are affecting the product quality. These shrinkage defects are not visible and these defects are visible
when the component subjected to machining at that area.
The above analysis is very useful for the diecasters to reduce the scrap rates. The defects and root causes will
be identified by experienced diecaster and analysis can be made according to the defect. If the defects in the
high pressure diecasting process are reduced then the margin of the company will leads to higher level. These
defects are one of the hidden losses which can be identified easily by the experienced diecasters. Some of the
OEM customers like HONDA, MARUTHI, HERO, FORD and TVS are required 100 PPM in HPDC process
machined component. This will increase the line efficiency and more productivity improvement. Finally the end
customer also will happy with the product.
The HPDC line efficiency will be calculated based upon the quality rating. In the HPDC the OEE
(Overall Equipment Effectiveness) plays a vital role in the diecasting industry. The OEE is calculated as
multiplication of, A (Availability), P (Performance) and Q (Quality rating) i.e. A X P X Q.If the quality rating is
decrease the OEE will be reduced. If the OEE is more than 85% the company known as world class
manufacturing company.

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